AN OVERVIEW OF CNC MACHINES ( 1 ) Historical Perspective The word NC which stands for numerical control refer to control of a machine

or a process using symbolic codes consisting of characters and numerals. The word CNC came into existence in seventies when microprocessors and microcomputers replaced integrated circuit IC based controls used for NC machines. The development of numerical control owes much to the United States air force. The concept of NC was proposed in the late 1940s by John Parsons who recommended a method of automatic machine control that would guide a milling cutter to produce a curvilinear motion in order to generate smooth profiles on the work-pieces. In 1949, the U.S Air Force awarded Parsons a contract to develop new type of machine tool that would be able to speed up production methods. Parsons sub-contracted the Massachusetts Institute of Technology (MIT) to develop a practical implementation of his concept. Scientists and engineers at M.I.T built a control system for a two axis milling machine that used a perforated paper tape as the input media. This prototype was produced by retrofitting a conventional tracer mill with numerical control servomechanisms for the three axes of the machine. By 1955, these machines were available to industries with some small modifications. The machine tool builders gradually began developing their own projects to introduce commercial NC units. Also, certain industry users, especially airframe builders, worked to devise numerical control machines to satisfy their own particular production needs. The Air force continued its encouragement of NC development by sponsoring additional research at MIT to design a part programming language that could be used in controlling N.C. machines. In a short period of time, all the major machine tool manufacturers were producing some machines with NC, but it was not until late 1970s that computer-based NC became widely used. NC matured as an automation technology when electronics industry developed new products. At first, miniature electronic tubes were developed, but the controls were big, bulky, and not very reliable. Then solid-state circuitry and eventually modular or integrated circuits were developed. The control unit became smaller, more reliable, and less expensive. (2) Computer Numerical Control Computer numerical control (CNC) is the numerical control system in which a dedicated computer is built into the control to perform basic and advanced NC functions. CNC controls are also referred to as softwired NC systems because most of their control functions are implemented by the control software programs. CNC is a computer assisted process to control general purpose machines from instructions generated by a processor and stored in a memory system. It is a specific form of control system where position is the principal controlled variable. All numerical control machines manufactured since the seventies are of CNC type. The computer allows for the following: storage of additional programs, program editing, running of program from memory, machine and control diagnostics, special routines, inch/metric, incremental/absolute switchability. CNC machines can be used as stand alone units or in a network of machines such as flexible machine centres. The controller uses a permanent resident program called an executive program to process the codes into the electrical pulses that control the machine. In any CNC machine, executive program resides in ROM and all the NC codes in RAM. The information in ROM is written into the electronic chips and cannot be erased and they become active whenever the machine is on. The contents in RAM are lost when the controller is turned off. Some use special type of RAM called CMOS memory, which retains its contents even when the power is turned off.

( 1.3 ) Direct Numerical Control In a Direct Numerical Control system (DNC), a mainframe computer is used to coordinate the simultaneous operations of a number NC machines as shown in the figures 21.2 & 21.3. The main tasks performed by the computer are to program and edit part programs as well as download part programs to NC machines. Machine tool controllers have limited memory and a part program may contain few thousands of blocks.So the program is stored in a separate computer and sent directly to the machine, one block at a time. First DNC system developed was Molins System 24 in 1967 by Cincinnati Milacron and General Electric. They are now referred to as flexible manufacturing systems (FMS). The computers that were used at those times were quite expensive

Fig 21.2 DNC System

21.4 Advantages & Disadvantages of CNC machine tools

Figure 21.4 (a) Manually operated milling

Figure 21.4 (b) Computer controlled machine milling machine

Some of the dominant advantages of the CNC machines are:

CNC machines can be used continuously and only need to be switched off for occasional maintenance. These machines require less skilled people to operate unlike manual lathes / milling machines etc. CNC machines can be updated by improving the software used to drive the machines. Training for the use of CNC machines can be done through the use of 'virtual software'. The manufacturing process can be simulated virtually and no need to make a prototype or a model. This saves time and money. Once programmed, these machines can be left and do not require any human intervention, except for work loading and unloading. These machines can manufacture several components to the required accuracy without any fatigue as in the case of manually operated machines. Savings in time that could be achieved with the CNC machines are quite significant. Some of the disadvantages of the CNC machines are:

CNC machines are generally more expensive than manually operated machines. The CNC machine operator only needs basic training and skills, enough to supervise several machines. Increase in electrical maintenance, high initial investment and high per hour operating costs than the traditional systems. Fewer workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment.

( 5 ) Applications of NC/CNC machine tools CNC was initially applied to metal working machinery: Mills, Drills, boring machines, punch presses etc and now expanded to robotics, grinders, welding machinery, EDM's, flame cutters and also for inspection equipment etc. The machines controlled by CNC can be classified into the following categories: CNC mills and machining centres.

CNC lathes and turning centers CNC EDM CNC grinding machines CNC cutting machines (laser, plasma, electron, or flame) CNC fabrication machines (sheet metal punch press, bending machine, or press brake) CNC welding machines CNC coordinate measuring machines

CNC Coordinate Measuring Machines: A coordinate measuring machine is a dimensional measuring device, designed to move the measuring

probe to determine the coordinates along the surface of the work piece. Apart from dimensional measurement, these machines are also used for profile measurement, angularity, digitizing or imaging. A CMM consists of four main components: the machine, measuring probe, control system and the measuring software. The control system in a CMM performs the function of a live interaction between various machine drives, displacement transducers, probing systems and the peripheral devices. Control systems can be classified according to the following groups of CMMs. 1. Manually driven CMMs 2. Motorized CMMs with automatic probing systems 3. Direct computer controlled (DCC) CMMs 4. CMMs linked with CAD, CAM and FMS etc. The first two methods are very common and self explanatory. In the case of DCC CMMs, the computer control is responsible for the movement of the slides, readout from displacement transducers and data communication. CMM are of different configurations-fixed bridge, moving bridge, cantilever arm figure 21.5(a), horizontal arm and gantry type CMM as shown in figure 21.5(b).

Figure 21.5(a) Cantilever type CMM

Figure 21.5(b) Gantry type CMM

(6 ) CNC welding machines:

Figure 21.6 4 axis CNC Tig welding machine

The salient features of CNC welding machines are:

Superior quality and weld precision. These machines are also equipped with rotary tables. Weld moves, welding feed rate, wire feed, torch heights & welding current can be programmed. CNC welding machines are used for laser welding, welding of plastics, submerged arc welding, wire welding machines, butt welding, flash butt welding etc. These machines are generally used in automobile work shops Cost of these machines will be twice than the conventional welding machines.

CNC EDM & WEDM machines: EDM is a nontraditional machining method primarily used to machine hard metals that could not be machined by traditional machining methods. Material removal will be taking place by a series of electric arcs discharging across the gap between the electrode and the work piece. There are two main types- ram EDM & wire cut EDM. In wire-cut EDM, a thin wire is fed through the work piece and is constantly fed from a spool and is held between upper and lower guides. These guides move in the x-y plane and are precisely controlled by the CNC. Wire feed rate is also controlled by the CNC.

Figure 21.6 (a) Ram EDM

Figure 21.6 (b) Wire cut EDM